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Application - Power

Factor Correction
(PFC) with XMCTM
XMC™ microcontrollers
July 2016
Agenda

1 Key features

2 Specification

3 System block diagram

4 Software overview

5 Highlight MCU features

6 CCM PFC control scheme

Copyright © Infineon Technologies AG 2016. All rights reserved. 2


Agenda

1 Key features

2 Specification

3 System block diagram

4 Software overview

5 Highlight MCU features

6 CCM PFC control scheme

Copyright © Infineon Technologies AG 2016. All rights reserved. 3


Power Factor Correction (PFC) with XMC™
Key features
Target Application
› Server Power Supply
› Telecom Power Supply

Key Features
› Continuous Conduction Mode scheme with XMC4200 & XMC1300
› Average Current Mode Control
– Pure digital control: Discrete control loops
› Fixed frequency, adjustable depending on input lines
– 100 kHz at low line, 130 kHz at high line for XMC4200
– 100 kHz at both lines for XMC1300
– Duty feed-forward at low line for improved performance
› Includes standard features from analog PFC IC:
– Soft start, Brown-in/out
– Protections: OVP, OCP, OPP

Copyright © Infineon Technologies AG 2016. All rights reserved. 4


Agenda

1 Key features

2 Specification

3 System block diagram

4 Software overview

5 Highlight MCU features

6 CCM PFC control scheme

Copyright © Infineon Technologies AG 2016. All rights reserved. 5


Power Factor Correction (PFC) with XMC™
specification

Specifications
› Input Voltage range: 90 Vac – 264 Vac
› Output Voltage: 395 Vdc
› Power Factor: >0.95 at operating range
› Total Harmonic Distortion: <10%
› Efficiency: ~97%

Copyright © Infineon Technologies AG 2016. All rights reserved. 6


Agenda

1 Key features

2 Specification

3 System block diagram

4 Software overview

5 Highlight MCU features

6 CCM PFC control scheme

Copyright © Infineon Technologies AG 2016. All rights reserved. 7


Power Factor Correction (PFC) with XMC™
Typical architecture for PSU

› A power supply usually has the following elements:


– Rectifier (diode bridge or active rectifiers)  rectifies the AC signal into high
voltage DC
– PFC  ensures a good current shape (PF close or equal to 1) to maximize
active power. Commonly a PFC Boost stage
– DC-DC converter reduces the high voltage. In many cases isolates electrically
the power supply into primary and secondary. Common stages converters
here are LLC, Full/Half Bridges, Flyback converters, Forward, etc.
– Optional DC-DC „Point of load“ permits different voltage outputs.
Different converters can be used depending on the needs: Buck, Boost (if
higher DC voltage is needed), Flyback, etc

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Power Factor Correction (PFC) with XMCTM
PFC basics (1/2)
› Power Factor Correction

– Forcing input current to be in the same phase and same shape as input voltage,
making the load to appear as pure resistive load
– Improved Power Factor (and THD) results in better overall system efficiency
– PFC circuit is accomplished by adding a DC-DC Boost Converter after rectifier
– Two modes of operation: Continuous Conduction Mode (CCM) and Critical
Conduction Mode (CRM)
› Without PFC › With PFC

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Power Factor Correction (PFC) with XMCTM
PFC basics (2/2)
› Critical Conduction Mode › Continuous Conduction Mode

– Lower average output current – Higher average output current


– Used for low power application (<300 W) – Used for high power application
(>300 W)
– Variable switching frequency, constant
ON-time – Constant switching frequency, variable
ON-time
– Switched every time inductor current goes
to zero – Use Average Current Mode control.
Current Reference determine ON-time
– Less calculation, only requires voltage
to regulate the inductor current
loop. The rest of the functionality is done
with MCU peripheral – Calculation intensive, high CPU load

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Power Factor Correction (PFC) with XMCTM
CCM PFC with XMC4200

Inductor Current
Vout
Vin

XMC4200
VADC VADC VADC
Vin IL Vout
Iact Duty
Current cycle Vact
Compensator CCU8
PWM
ICMD OPP
Iref Duty Out
FeedFwd
Filter Ext Modu
Feedforward
Filter
CMP
Over Current ERU
Protection
Brown-in OVP
DAC
Brown-out OCP Ref

Inverse Voltage
Square Compensator
Vref

System block diagram: CCM PFC with XMC4200

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Power Factor Correction (PFC) with XMCTM
CCM PFC with XMC1300

Inductor Current
V out
V in

XMC1300
VADC VADC VADC
Vin IL Vout
Iact
Current Duty Vact
Compensator cycle CCU8
ICMD OCP PWM Out
Iref Duty
FeedFwd
Filter
Feedforward
Filter

Brown-in OVP
Brown-
out

Inverse Voltage
Square Compensator
Vref

System block diagram: CCM PFC with XMC1300

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Agenda

1 Key features

2 Specification

3 System block diagram

4 Software overview

5 Highlight MCU features

6 CCM PFC control scheme

Copyright © Infineon Technologies AG 2016. All rights reserved. 13


Power Factor Correction (PFC) with XMCTM
Software overview

Brown
Out/
PFC off

› Possible PFC states


Vin < 85 || Vin > 264 with triggers to the
Over next states
Soft
Power
start
Prot. › PFC firmware is
interrupt-based, not
Steady state-machine based to
State
ensure real-time
behavior

Over Over
Voltage Current
Prot. Prot.

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Agenda

1 Key features

2 Specification

3 System block diagram

4 Software overview

5 Highlight MCU features

6 CCM PFC control scheme

Copyright © Infineon Technologies AG 2016. All rights reserved. 15


Highlight MCU features
Overview

XMC1000 family: XMC4000 family:


› 32 MHz ARM® Cortex™- M0 › 80/120 MHz ARM® Cortex™- M4
with optional 2x peripheral clock with built in DSP, FPU, MPU and DMA
boost (64 MHz) › 20 ~ 160 kB RAM, 64 kB ~ 1 MB
› 16 kB RAM, 8 ~ 200 kB Flash with Flash with ECC and up to 4 kB Cache
ECC › Peripherals running up to 80/120
› Peripherals running up to 64 MHz MHz
› 1.8 ~ 5.5 Volt VDD › High Resolution PWM (150 ps) and
› Operating up to 105°C smart comparators with slope
compensation
› Operating up to 125°C

› Integration of peripherals analog-mixed signal, Timing/PWM and


communication with flexible IO muxing in small packages
› Free DAVE™ IDP and DAVE™ Apps (SW Library with optimized and tested
code) with GUI and code generation, open to 3rd party tools

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Highlight MCU features
Smart analog comparators (1/2)

› XMC4000 comparators include filtering, blanking and clamping capabilities as


well as a DAC for automatic reference or slope generation
› XMC1000 comparators can configure hysteresis and output filtering and have
a bandwidth of 30 ns

Support almost
any topology

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Highlight MCU features
Smart analog comparators (2/2)

› Can easily and efficiently › Analog frontend digitally controlled


perform:
› Best of both worlds:
– Voltage control
– Current control – Analog performance
– Customized controls – Programmability/flexibility
– Protection features

› Supports almost any


topology and combinations:
– Boost/buck
– PSFB, LLC
– PFCs
– Flybacks/forwards
– Inverters
– Etc…

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Highlight MCU features
Fast and flexible ADC + timers (1/2)

› In order to cover the crucial requirements of power supplies, it is


needed to provide:

– Flexible and safe PWM patterns


– Fast ADC sampling
– Flexible ADC sequencing and synchronization to PWM
– Post processing of conversions including
– Filtering (FIR/IIR), FIFO, subtraction (for offset compensation),
etc.
– Resolution in sampling signal and in PWM for accurate control:
– 12 bits ADC
– 150 ps max resolution PWM in XMC4 and 15,6 ns in XMC1000

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Highlight MCU features
Fast and flexible ADC + timers (2/2)

› For power conversion continues and discontinues PWM signals have to be


generated – switching between the two modes is needed to get efficiency over
a wide load range
› CCU4/CCU8 supports any kind of pulse generation like
– Asymmetric PWM
– Aperiodic PWM
– Single events and pulses
› CCU4/CCU8 can be controlled
from external or internal events
– External start / stop
– Emergency trap
– Override/modulation
– Count gating
– Capturing

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Highlight MCU features
Additional features

› ERU module allows an almost all to all connection of signals in


XMCTM. This is helpful in cases such as:
– Detect a peak current with a comparator and send the signal
to a timer  usually signal is directly connected
– But if the comparator signal needs to be OR-ed with another
one, this can be done with the available logic functions in
ERU module

› Serial communications, like I2C for PMBUS, and CAN supported

Copyright © Infineon Technologies AG 2016. All rights reserved. 21


Agenda

1 Key features

2 Specification

3 System block diagram

4 Software overview

5 Highlight MCU features

6 CCM PFC control scheme

Copyright © Infineon Technologies AG 2016. All rights reserved. 22


Power Factor Correction (PFC) with XMCTM
CCM PFC control scheme with XMC4200

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Power Factor Correction (PFC) with XMCTM
XMC4200 interconnects

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Power Factor Correction (PFC) with XMCTM
CCM PFC control scheme with XMC1300

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Power Factor Correction (PFC) with XMCTM
XMC1300 interconnects

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Power Factor Correction (PFC) with XMCTM
duty-ratio feedforward

› Smoothen the duty cycle value produced by current loop with feedforward filter
› Improved Power Factor and THD
› Implemented in firmware current loop
D. M. Van de Sype, K. De Gussemé, A. P. M. Van den Bossche, J. A. Melkebeek,
“Duty-Ratio Feedforward for Digitally Controlled Boost PFC Converters”, IEEE
Transactions on Industrial Electronics, Vol. 52, No. 1, February 2005

Copyright © Infineon Technologies AG 2016. All rights reserved. 27


Power Factor Correction (PFC) with XMCTM
brown-in/ brown-out

› Designed to ensure
PFC is able to reset
itself if a brown-out is
detected and start
itself if a brown-in is
detected
› Accomplished by
detecting the input
voltage rms value
– Embedded in the
voltage loop

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Power Factor Correction (PFC) with XMCTM
soft start

› Designed to ensure
smooth PFC start-up with
lesser inrush input current
› Accomplished by
incrementing voltage loop
reference from minimum
to desired output voltage
(e.g. 395 Vdc)
– Embedded in the
voltage loop
Wait until Vin feedforward filter result is stable
› Adjustable timing
Initialize control loop
– By changing the voltage
Set voltage reference to current output voltage counter in the firmware

Increment voltage reference until desired level


(e.g. 395 V)

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Power Factor Correction (PFC) with XMCTM
Over Voltage Protection (OVP)

› Output overvoltage normally occurs at


sudden no-load or step load from high-
load to low-load

› PWM output is switched off until the


output voltage goes down to certain
level and it will be switched on again

› Use VADC0 Group 0 boundaries set at


455 V and 375 V

› Ideally, interrupt should happen once.


Practically, it will happen many times

– Counting mechanism to ensure


overvoltage/undervoltage conditions
are met
– The ISR will be disabled after it is
served

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Power Factor Correction (PFC) with XMCTM
analog Over Current Protection (OCP)

› Designed to protect MOSFET


› OCP level is set according to MOSFET
rating
› Accomplished with XMC4200 CSG and
DAC and CCU8 external modulation
feature
› Inductor current is compared with OCP
level
› OCP level is set in firmware
› CSG output is passed through ERU
– Technically it is possible to pass
through CSG output to CCU8
› PWM output is modulated by CSG
output

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Power Factor Correction (PFC) with XMCTM
Digital Over Current Protection (OCP)

› Designed to limit the maximum power passing through the PFC

› OPP normally happens when PFC has step load from low load close to maximum rated load

› Accomplished by limiting Current Command in the firmware

– This will clamp inductor current to maximum value defined in the firmware
– Output voltage will drop. As a result, constant power is maintained
› Similar to OCP but it is set at lower current level

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General information

› Where to buy XMCTM starter kit?


– http://www.infineon.com/xmc-dev

› For latest updates, please refer to:


– http://www.infineon.com/xmc1000
– http://www.infineon.com/xmc4000

› For support:
– http://www.infineonforums.com

Copyright © Infineon Technologies AG 2016. All rights reserved. 33


Support material

Collaterals and › Product Briefs › www.infineon.com/XMC


Brochures › Selection Guides
› Application Brochures
› Presentations
› Press Releases, Ads

Technical Material › Application Notes › www.infineon.com/XMC


› Technical Articles › Kits and Boards
› Simulation Models › DAVETM
› Datasheets, MCDS Files › Software and Tool Ecosystem
› PCB Design Data

Videos › Technical Videos › Infineon Media Center


› Product Information › XMC Mediathek
Videos

Contact › Forums › Infineon Forums


› Product Support › Technical Assistance Center (TAC)

Copyright © Infineon Technologies AG 2016. All rights reserved. 34


Disclaimer
The information given in this training materials is given as a hint for
the implementation of the Infineon Technologies component only and
shall not be regarded as any description or warranty of a certain
functionality, condition or quality of the Infineon Technologies
component.

Infineon Technologies hereby disclaims any and all warranties and


liabilities of any kind (including without limitation warranties of non-
infringement of intellectual property rights of any third party) with
respect to any and all information given in this training material.
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